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Nondestructive Testing Reference Standards: Utilization, Manufacturing and Custom Applications Phil Herman

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No

nd

est

ruct

ive

Te

stin

g R

efe

ren

ce S

tan

da

rds:

Uti

liza

tio

n,

Ma

nu

fact

uri

ng

an

d C

ust

om

Ap

pli

cati

on

s

Ph

il H

erm

an

Pre

sen

ter:

P

hil

He

rma

n,

Pre

sid

en

t/C

EO

PH

To

ol

Re

fere

nce

Sta

nd

ard

s, L

LC.

�C

om

pan

y fo

un

de

d in

19

73

as

ma

nu

fact

ure

r o

f m

old

s

�In

vest

me

nt

in E

DM

te

chn

olo

gy in

late

19

70

’s le

d t

o

ND

T w

ork

�P

ion

ee

r in

art

ific

ial d

efe

ct m

ach

inin

g in

pip

e a

nd

tu

be

�T

we

nty

ye

ars

as

exe

cuti

ve le

ad

er

of

com

pa

ny

�R

eco

gniz

ed

lead

er

in m

an

ufa

ctu

re o

f R

efe

ren

ce

Sta

nd

ard

s a

nd

Ca

libra

tio

n B

lock

s

Pre

sen

ter:

P

hil

He

rma

n,

Pre

sid

en

t/C

EO

PH

To

ol

Re

fere

nce

Sta

nd

ard

s, L

LC.

Cu

rre

nt

job

�O

vers

ee

op

era

tio

ns,

wo

rk w

ith

OE

Ms

an

d

ind

ust

ry e

xpe

rts

on

ne

w b

lock

de

sign

s, s

up

po

rt

sale

s to

en

d-u

ser

clie

nts

an

d d

eale

rs w

orl

dw

ide

�U

niq

ue

op

po

rtu

nit

y to

su

pp

ort

nu

me

rou

s

ind

ust

rie

s in

clu

din

g, O

il a

nd

Ga

s, P

ow

er

Ge

ne

rati

on

, Ae

rosp

ace

, Pri

ma

ry M

eta

ls, D

ep

t.

of

De

fen

se, R

&D

, an

d m

an

y m

ore

�P

urp

ose

of

Pre

sen

tati

on

�W

ha

t a

re R

efe

ren

ce S

tan

da

rds?

�D

isti

nct

ion

be

twe

en

Re

fere

nce

Sta

nd

ard

s

an

d C

ali

bra

tio

n B

lock

s

�H

ow

are

ea

ch u

sed

?

�C

riti

cal

asp

ect

s o

f m

an

ufa

ctu

re a

nd

insp

ect

ion

�In

tere

stin

g C

ust

om

Ap

pli

cati

on

s a

nd

th

e

late

st i

n s

tan

da

rd d

esi

gn

s

So

me

OIL

an

d G

AS

in

du

stry

FA

ST

FA

CT

S:

•A

me

rica

’s o

il a

nd

na

tura

l ga

s in

du

stry

su

pp

ort

s 9

.2

mil

lion

job

s a

nd

co

mp

rise

s 7

.5 p

erc

en

t o

f G

DP

.

•T

he

na

tio

nal

ave

rage

an

nu

al s

ala

ry f

or

oil

an

d g

as

exp

lora

tio

n a

nd

pro

du

ctio

n is

$9

6,8

44

or

ab

ou

t $

47

pe

r h

ou

r –

mo

re t

ha

n d

ou

ble

th

e a

vera

ge a

nn

ua

l

sala

ry o

f a

ll o

ccu

pa

tio

ns.

•Fr

om

20

04

-20

07

, th

e o

il a

nd

na

tura

l ga

s in

du

stry

wa

s re

spo

nsi

ble

fo

r cr

ea

tin

g n

ea

rly

2 m

illio

n

ad

dit

ion

al d

om

est

ic jo

bs.

Co

pyri

gh

t 2

01

0 –

Am

eri

ca

n P

etr

ole

um

In

stitu

te,

all

righ

ts

rese

rved

. A

PI C

om

mu

nic

atio

ns:

20

10

-17

4 | 1

0.1

5.1

0 | P

DF

So

me

OIL

an

d G

AS

in

du

stry

FA

ST

FA

CT

S:

•T

he

U.S

. co

nsu

me

s a

bo

ut

19

.5 m

illio

n

ba

rre

ls/d

ay

. A

ba

rre

l of

oil

con

tain

s 4

2

ga

llon

s. S

o,

tha

t’s

82

0 m

illi

on

ga

llo

ns

of

oil

pe

r d

ay

div

ide

d b

y 3

00

mil

lio

n,

wh

ich

giv

es

a

pe

r p

ers

on

, p

er

da

y c

on

sum

pti

on

of

ap

pro

xim

ate

ly 2

.7 g

all

on

s, w

hic

h e

qu

als

ap

pro

xim

ate

ly 2

ba

rre

ls o

f o

il p

er

mo

nth

,

pe

r p

ers

on

.

Co

pyri

gh

t 2

01

0 –

Am

eri

ca

n P

etr

ole

um

In

stitu

te,

all

righ

tsre

se

rved

. A

PI C

om

mu

nic

atio

ns:

20

10

-17

4 | 1

0.1

5.1

0 | P

DF

Th

e R

ole

of

ND

T i

n t

he

Oil

an

d G

as

ind

ust

ry

•N

o m

atte

r h

ow

we

ge

t a

t it

, we

ne

ed t

o g

et

it t

o a

re

fin

ery

an

d

ult

ima

tely

to

th

e c

on

sum

er.

•T

his

mu

st b

e d

on

e in

th

e sa

fest

man

ne

r p

oss

ible

.

•N

on

de

stru

ctiv

e T

est

ing

(ND

T)

ensu

res

tha

t th

is c

riti

cal g

oal

is

ach

ieve

d.

•M

uch

of

the

eq

uip

me

nt

in o

ur

ind

ust

ry i

s m

eta

l an

d m

eta

ls f

ail.

•N

DT

he

lps

ow

ne

rs a

nd

op

era

tors

to

loca

te it

em

s o

f p

ote

nti

al

fail

ure

be

fore

th

ey

cre

ate

pro

ble

ms.

•C

rack

ing,

Co

rro

sio

n,

Pit

tin

g, W

all

Loss

, an

d m

ore

.

Wh

at

are

Re

fere

nce

Sta

nd

ard

s?

•Si

nce

re

al o

r a

ctu

al f

law

ed

sp

eci

men

s a

re d

iffi

cult

to

ob

tain

an

d e

ven

mo

re d

iffi

cult

to

qu

anti

fy, N

DT

R

efe

ren

ce S

tan

da

rds

serv

e a

vit

al r

ole

.

•T

he

y a

re a

ctu

al it

em

s to

be

insp

ect

ed

into

wh

ich

a

rtif

icia

l, p

reci

se d

efe

cts

are

intr

od

uce

d v

ia

ma

chin

ing

me

tho

ds.

•T

he

de

fect

s re

pre

sen

t a

va

rie

ty o

f u

nd

esi

rab

le

con

dit

ion

s in

va

ryin

g d

egr

ee

s o

f se

veri

ty.

•In

th

is w

ay,

Re

fere

nce

Sta

nd

ard

s p

rovi

de

re

pe

ata

ble

ND

T in

spe

ctio

n r

esu

lts

tha

t al

low

in

spe

ctio

n p

ers

on

nel

to

ma

ke a

cce

pt/

reje

ct

de

cisi

on

s.

Wh

at

are

Re

fere

nce

Sta

nd

ard

s?

He

re a

re a

fe

w e

xa

mp

les:

•P

ipe

s w

ith

ED

M n

otc

he

s, f

lat-

bo

tto

m

or

sid

e-d

rille

d h

ole

s

•T

ub

es

wit

h n

otc

he

s o

n I

D a

nd

OD

, p

its,

we

ar

•Li

ftin

g g

ea

r w

ith

sim

ula

ted

cra

ckin

g

•T

hre

ad

ed

Co

up

lers

•T

urb

ine

Bla

de

s

�So

me

exa

mp

les

of

Ref

ere

nce

Sta

nd

ard

s

ASM

E S

ec.

V A

rtic

le 4

An

gle

Be

am

Pip

e S

tan

da

rds

wit

h 1

0%

de

ep

fla

ws

for

UT

�So

me

exa

mp

les

of

Ref

ere

nce

Sta

nd

ard

s

Die

sel

Pis

ton

in

alu

min

um

wit

h E

DM

slo

ts m

ach

ine

d i

n c

om

bu

stio

n b

ow

l fo

r E

dd

y C

urr

en

t

�So

me

exa

mp

les

of

Ref

ere

nce

Sta

nd

ard

s

Forg

ed

all

oy

ste

el n

ozz

le w

ith

OD

an

d I

D n

otc

he

s fo

r U

ltra

son

ic I

nsp

ect

ion

Wh

at

are

Ca

lib

rati

on

Blo

cks?

•A

no

n-r

ep

rese

nta

tive

blo

ck c

on

tain

ing

pre

cisi

on

-m

ach

ined

ge

om

etr

ies

(th

ickn

ess

es,

ra

dii

, an

gle

s,

ho

les

an

d s

lots

) th

at

are

use

d t

o c

alib

rate

or

set-

up

N

DT

eq

uip

me

nt.

•B

lock

use

d t

o “

sta

nd

ard

ize

”N

DT

inst

rum

en

ts,

the

reb

y e

nsu

rin

g p

rop

er

fun

ctio

n, a

nd

th

e a

bili

ty t

o

pe

rfo

rm t

he

re

qu

ire

d in

spe

ctio

n w

ith

co

nfi

de

nce

.

•W

ith

ou

t ca

libra

tio

n s

tan

da

rds,

ND

T p

ers

on

ne

l are

u

nab

le t

o m

ove

fo

rwa

rd w

ith

th

e in

spe

ctio

n

pro

cess

.

•B

oth

ca

libra

tio

n b

lock

s a

nd

re

fere

nce

sta

nd

ard

s m

ust

be

ma

nu

fact

ure

d w

ith

utm

ost

ca

re a

nd

a

ccu

racy

. A

po

orl

y-m

an

ufa

ctu

red

or

un

cert

ifie

d

sta

nd

ard

pu

ts s

ub

seq

ue

nt

test

ing

in d

ou

bt.

•M

an

ufa

ctu

rers

en

sure

dim

en

sio

na

l in

tegr

ity

thro

ugh

an

arr

ay

of

QA

re

qu

ire

me

nts

th

at

en

sure

“t

race

ab

ility

to

na

tio

na

l sta

nd

ard

s”su

ch a

s N

IST

.

Wh

at

are

Ca

lib

rati

on

Blo

cks?

•A

fe

w e

xam

ple

s:

–S

tep

Blo

cks

for

ult

raso

nic

th

ick

ne

ss

calib

rati

on

–II

W T

est

Blo

cks

for

an

gle

be

am

veri

fica

tio

n,

dis

tan

ce c

alib

rati

on

,

sen

siti

vity

an

d m

ore

–H

ori

zon

tal a

nd

Ve

rtic

al

Lin

ea

rity

blo

cks

–A

ST

M f

lat-

bo

tto

m h

ole

blo

cks

�So

me

exa

mp

les

of

Ca

libra

tio

n B

lock

s

Tw

o t

ype

s o

f U

ltra

son

ic T

hic

kne

ss B

lock

s fo

r a

ccu

rate

in

stru

me

nt

cali

bra

tio

n

�So

me

exa

mp

les

of

Ca

libra

tio

n B

lock

s

IIW

-Typ

e 2

Ult

raso

nic

Te

st B

lock

�So

me

exa

mp

les

of

Ca

libra

tio

n B

lock

s

AST

M E

42

8 F

lat

Bo

tto

m H

ole

Dis

tan

ce A

mp

litu

de

se

t o

f 1

9 b

lock

s w

ith

#3

(3

/64

”) F

BH

Cri

tica

l a

spe

cts

of

Ma

nu

fact

uri

ng

an

d I

nsp

ect

ion

�E

lect

rica

l Dis

cha

rge

Ma

chin

ing

in m

an

ufa

ctu

rin

g

sim

ula

ted

fla

ws/

de

fect

s

�T

he

pro

cess

of

ma

nu

fact

uri

ng

ED

M N

otc

h R

efe

ren

ce

Sta

nd

ard

s

�C

on

ven

tio

nal

Ma

chin

ing

of

Cal

ibra

tio

n B

lock

s

Ele

ctri

cal

Dis

cha

rge

Ma

chin

ing

(E

DM

)

•E

DM

is

a m

eta

lwo

rkin

g o

pe

rati

on

uti

lizi

ng

sp

ark

ero

sio

n f

or

pre

cise

sh

ap

ing

of

the

me

tal

wo

rkp

iece

.

Th

e w

ork

pie

ce(a

no

de

) a

nd

ele

ctri

cal

too

l (e

lect

rod

e)

are

su

bm

erg

ed

in

a b

ath

of

die

lect

ric

flu

id a

nd

bro

ug

ht

clo

ser

tog

eth

er

un

til

the

vo

lta

ge

ov

erc

om

es

the

insu

lati

ng

eff

ect

of

the

flu

id,

cau

sin

g a

sp

ark

be

twe

en

the

ele

ctro

de

an

d w

ork

pie

ce.

Co

nse

cuti

ve

dis

cha

rge

s

pro

du

ce a

se

rie

s o

f m

icro

-cra

ters

on

th

e w

ork

pie

ce

un

til

the

de

sire

d s

ha

pe

is

ach

iev

ed

.

Sinker EDM

Sinker EDM

Sinker EDM

Sinker EDM

(Electrode in yellow)

(Electrode in yellow)

(Electrode in yellow)

(Electrode in yellow)

Wire EDM

Wire EDM

Wire EDM

Wire EDM

(Electrode in yellow)

(Electrode in yellow)

(Electrode in yellow)

(Electrode in yellow)

Ad

va

nta

ge

s o

f E

DM

ov

er

con

ve

nti

on

al

“ch

ip-m

ak

ing

ma

chin

ing

me

tho

ds

in m

ak

ing

ND

T S

tan

da

rds:

•T

he

ab

ilit

y t

o m

ach

ine

ex

tre

me

ly n

arr

ow

no

tch

es

(un

de

r .0

01

”)

•T

he

ab

ilit

y t

o a

cce

ss h

ard

-to

-re

ach

lo

cati

on

s

such

as

pip

e/t

ub

e I

Ds

wit

ho

ut

the

ne

ed

to

sect

ion

th

e w

ork

pie

ce.

•T

he

ab

ilit

y t

o h

old

ve

ry c

lose

dim

en

sio

na

l

tole

ran

ces.

•T

he

ab

ilit

y t

o m

ach

ine

ha

rde

r m

ate

ria

ls a

nd

ex

oti

c a

llo

ys.

Ad

va

nta

ge

s o

f E

DM

ov

er

con

ve

nti

on

al

“ch

ip-m

ak

ing

ma

chin

ing

me

tho

ds

in m

ak

ing

ND

T S

tan

da

rds:

•T

he

ab

ilit

y t

o m

ach

ine

irr

eg

ula

r sh

ap

es

no

t

oth

erw

ise

po

ssib

le.

•A

ll c

on

du

ctiv

e m

ate

ria

ls a

re a

ble

to

be

ED

M'd

. E

DM

no

tch

es

can

be

ma

chin

ed

on

bo

th t

he

OD

an

d I

D o

f p

ipe

an

d t

ub

e.

No

tch

es

can

be

ma

chin

ed

on

ID

s a

s sm

all

as

0.0

40

".

Ty

pic

al

ED

M N

otc

h p

roce

ss

•It

em

arr

ive

s a

t P

H T

oo

l a

nd

is

un

iqu

ely

id

en

tifi

ed

.

•D

raw

ing

s a

re p

rep

are

d.

•W

ork

pie

cela

yo

ut

is c

om

ple

ted

.

•E

DM

pa

ram

ete

rs a

re e

sta

bli

she

d b

ase

d o

n n

otc

h

req

uir

em

en

ts/a

llo

y/p

rod

uct

sh

ap

e/s

ize

.

•E

DM

Ele

ctro

de

s a

re m

ad

e.

•W

ork

pie

ceis

fix

ture

do

n E

DM

ta

ble

.

•E

DM

te

st-c

ut

ma

y b

e p

erf

orm

ed

.

•“

Re

al”

no

tch

is

ma

chin

ed

. (E

DM

’ers

say

“b

urn

ed

”)

Th

e E

DM

pro

cess

(co

nti

nu

ed

)…

•E

lect

rod

e i

s re

tra

cte

d a

nd

th

e r

ep

lica

tio

n m

ate

ria

l is

m

ixe

d a

nd

ap

pli

ed

.

•R

ep

lica

(tw

o-p

art

sil

ico

ne

pro

du

ct)

is c

ross

-se

ctio

ne

d

an

d e

xa

min

ed

at

hig

h-m

ag

nif

ica

tio

n (

13

5 t

o 2

70

X)

on

V

ide

o M

ea

sure

me

nt

Sy

ste

m.

•N

otc

h “

As-

bu

ilt”

dim

en

sio

ns

are

re

cord

ed

on

th

e

rep

lica

ho

lde

r.

•A

dd

itio

na

l n

otc

he

s a

re m

ach

ine

d.

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ert

ific

ati

on

Re

po

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rov

idin

g N

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tra

cea

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pre

pa

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tan

da

rd i

s p

rep

are

d f

or

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rn s

hip

me

nt

to

cust

om

er.

Ite

m a

rriv

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at

PH

To

ol

an

d i

s u

niq

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ly

ide

nti

fie

d.

ED

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lect

rod

es

are

ma

de

.

Ex

am

ple

s o

f E

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Ele

ctro

de

s

•ID Notch electrodes for tubing standards

Mo

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xa

mp

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of

ED

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lect

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red

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ED

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ab

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ED

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s “b

urn

ed

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re N

otc

he

s…

Re

pli

cati

on

Ma

teri

al

is m

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d a

nd

ap

pli

ed

to n

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h

Re

pli

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oss

-se

ctio

ne

d a

nd

ex

am

ine

d a

t

hig

h-m

ag

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ica

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n (

13

5 t

o 2

70

X)

on

Vid

eo

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asu

rem

en

t S

yst

em

.

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nv

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l M

ach

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f

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l (m

ain

tain

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at

no

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ace

ab

ilit

y)

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of

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wri

tes

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m

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aw

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r p

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ck

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d p

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lls

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les

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en

gra

ve

se

ria

l n

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all

oy

, d

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rip

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n

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l In

spe

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n a

nd

pla

ce i

n i

nv

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tory

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go

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pli

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on

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ific

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on

to

NIS

T

Sta

nd

ard

Te

st B

lock

s UT of material

UT of material

UT of material

UT of material

Machining of IIW

Machining of IIW

Machining of IIW

Machining of IIW

blanks

blanks

blanks

blanks

CNC program and

CNC program and

CNC program and

CNC program and

verification

verification

verification

verification

Sta

nd

ard

Te

st B

lock

s

Profile milling

Profile milling

Profile milling

Profile milling

of Angle Beam

of Angle Beam

of Angle Beam

of Angle Beam

block on CNC

block on CNC

block on CNC

block on CNC

Peck

Peck

Peck

Peck- ---drilling of

drilling of

drilling of

drilling of

IIWIIWIIWIIW- ---Type 1

Type 1

Type 1

Type 1

block on CNC

block on CNC

block on CNC

block on CNC

Sta

nd

ard

Te

st B

lock

s

Polishing and

Polishing and

Polishing and

Polishing and

hand finishing

hand finishing

hand finishing

hand finishing

Test Block Inventory

Test Block Inventory

Test Block Inventory

Test Block Inventory

Sta

nd

ard

Te

st B

lock

s

Block Serial Nos.

Block Serial Nos.

Block Serial Nos.

Block Serial Nos.

are engraved for

are engraved for

are engraved for

are engraved for

traceability and

traceability and

traceability and

traceability and

tietietietie- ---in to

in to

in to

in to

Certification

Certification

Certification

Certification

Report

Report

Report

Report

Logo and Serial No.

Logo and Serial No.

Logo and Serial No.

Logo and Serial No.

application on Laser

application on Laser

application on Laser

application on Laser

Engraving System

Engraving System

Engraving System

Engraving System

�C

ust

om

ap

pli

cati

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s a

nd

th

e l

ate

st t

ren

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tan

da

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ca

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lock

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n

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all

er

fla

ws

(no

tch

es,

FB

Hs,

mic

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s)

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mb

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ded

or

Sub

-su

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ASM

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Qu

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lock

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ea

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an

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(pip

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ba

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or

UT

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nd

tim

es/

Em

erg

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cy s

erv

ice

s

�St

rin

gen

t Q

A r

eq

uir

em

en

ts a

nd

NIS

T t

race

ab

ility

as

“ho

me

-ma

de

”st

an

da

rds

are

exp

ose

d in

au

dit

s

Cro

ss-s

ect

ion

of

we

ld-e

mb

ed

de

d f

law

ma

chin

ed

by

ED

M (

sho

ws

he

igh

t a

nd

wid

th)

Cro

ss-s

ect

ion

of

we

ld-e

mb

ed

de

d f

law

ma

chin

ed

by

ED

M (

sho

ws

he

igh

t a

nd

le

ng

th)

Va

ria

tio

n f

rom

th

e “

Sta

nd

ard

”th

em

e

DSC blocks with

DSC blocks with

DSC blocks with

DSC blocks with radiussed

radiussed

radiussed

radiussed

scanning surfaces

scanning surfaces

scanning surfaces

scanning surfaces

Double

Double

Double

Double- ---

wide IIW

wide IIW

wide IIW

wide IIW- ---

type 2

type 2

type 2

type 2

block for

block for

block for

block for

wide

wide

wide

wide

transducers

transducers

transducers

transducers

Special wide step blocks in

Special wide step blocks in

Special wide step blocks in

Special wide step blocks in

titanium alloy

titanium alloy

titanium alloy

titanium alloy

Special thickness step blocks

Special thickness step blocks

Special thickness step blocks

Special thickness step blocks

Sta

nd

ard

s fo

r A

uto

ma

ted

an

d R

ob

oti

c

Insp

ect

ion

sy

ste

ms

req

uir

e a

hig

he

r le

ve

l

of

pre

cisi

on

.

Boeing Delta IV AUSS

Boeing Delta IV AUSS

Boeing Delta IV AUSS

Boeing Delta IV AUSS

Special thickness standard

Special thickness standard

Special thickness standard

Special thickness standard

with relieved steps

with relieved steps

with relieved steps

with relieved steps

measuring 1

measuring 1

measuring 1

measuring 1” ”””x 8x 8x 8x 8” ”””at .020

at .020

at .020

at .020” ”””

to .400

to .400

to .400

to .400” ”””thickness.

thickness.

thickness.

thickness.

Co

rro

sio

n S

am

ple

sca

n b

e m

ad

e u

sin

g

ele

ctro

de

s ca

st f

rom

act

ua

l, i

n-s

erv

ice

corr

od

ed

se

ctio

ns

of

air

cra

ft s

kin

or

pip

eli

ne

.

EDM corrosion is indistinguishable

EDM corrosion is indistinguishable

EDM corrosion is indistinguishable

EDM corrosion is indistinguishable

from real corrosion.

from real corrosion.

from real corrosion.

from real corrosion.

Ult

ra-N

arr

ow

ED

M N

otc

he

s

EDM notches for Magnetic Particle

EDM notches for Magnetic Particle

EDM notches for Magnetic Particle

EDM notches for Magnetic Particle

Inspection measuring less than 0.001

Inspection measuring less than 0.001

Inspection measuring less than 0.001

Inspection measuring less than 0.001” ”””

wide at depths up to .012

wide at depths up to .012

wide at depths up to .012

wide at depths up to .012” ”””in SPS

in SPS

in SPS

in SPS

fasteners

fasteners

fasteners

fasteners

Mic

roh

ole

sfo

r Li

qu

id P

en

etr

an

tT

est

Pro

ps

Typical Micro

Typical Micro

Typical Micro

Typical Micro- ---holes are .004

holes are .004

holes are .004

holes are .004- ---.006

.006

.006

.006” ”””diameter x

diameter x

diameter x

diameter x

.008

.008

.008

.008- ---.010

.010

.010

.010” ”””deep.

deep.

deep.

deep.

Holes can be machined in welds in plate, pipe,

Holes can be machined in welds in plate, pipe,

Holes can be machined in welds in plate, pipe,

Holes can be machined in welds in plate, pipe,

and fasteners. For Personnel qualification.

and fasteners. For Personnel qualification.

and fasteners. For Personnel qualification.

and fasteners. For Personnel qualification.

ED

M S

tart

er

No

tch

es

for

Cra

ck p

rop

ag

ati

on

Ph

il H

erm

an

Pre

sid

en

t/C

EO

PH

To

ol

Re

fere

nce

Sta

nd

ard

s, L

LC

Te

lfo

rd,

PA

26

7-2

03

-16

00

ph

il@

ph

too

l.co

m

ww

w.p

hto

ol.

com

Qu

est

ion

s